Microwave reflector



April 19, 1966 l. D. Rol-IN ETAL MICROWAVE REFLECTOR 4 Sheets-Sheet 2Filed Aug. 27. 1965 NN WN INVENTORS l.. El

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April 19, 1966 l. D. RoHN ETAL 3,247,516

MICROWAVE REFLECTOR Filed Aug. 27, 1963 4 Sheets-Sheet 5 ff in' 2z jf fzn /41 n n I NVEN TORS April 19, 1966 1. D. RoHN ETAL. 3,247,516

MICROWAVE REFLECTOR Filed Aug. 27 1963 l 4 Sheets-Sheet. 4

iilllllllllli United States Patent O 3,247,516 MICRGWAVE REFLECTOR IvanBwight Rohn, Washburn, and Richard A. Kleine, Peoria, Ill., assignors toRohn Manufacturing C0., Peoria, Ill., a corporation of illinois FiledAng. 27, 1963, Ser. No. 304,8il 8 Ciainis. (Cl. 343-890) 4 The presentinvention relates generally to a microwave reflector .and method ofmanufacture. This inven- .tion is more particularly concerned with a newand improved type of reflector which can be manufactured from a seriesof light-weight metal extrusions. Our new reector can be shipped inknock-down form, and can be more economically assembled and installedwith a minimum of elfort.

In the past, various types of microwave retiectors have been used. Thesereflectors have been of dierent sizes such as 6 X 8', 8 X l2 and 10 X15. These reectors were fabricated of one solid piece and have beenpacked in large crates and frequently shipped on railroad cars. Theseprior types of reflectors have been frequently damaged in shipping andhave been difficult to handle because of the bulky nature of the largecrates carrying such reflectors.

According to the present invention, we have developed a new and improvedmicrowave rellector comprised of a series of strip-type panels which canbe shipped in yknock-down form and quickly and conveniently snappedtogether at the places of installation. Excellent results have beenobtained where the strip-type panels are formed as extrusions havingmeans for permitting the extrusions to be snapped together in lockedassembly. Where the retlector is formed from a series of our extrusions,we have found that the reflector has a number of superiorcharacteristics. This reflector has a reilection face which is free ofrivet and bolt heads. The reflection face is flatter than prior types ofmicrowave reflectors. By forming the reiiector from interlockingextrusions, the reflector is of a more rigid construction which insureslonger life and decreases maintenance cost. Still an- -other importantadvantage of our knock-down type rellector is that the consumer cost issubstantially reduced as the rellector can be shipped in knock-down format a substantially reduced freight cost.

In view of the foregoing, an important object of this invention is toprovide a new and improved microwave reector having superior microwavereflecting characteristics over prior types of retiectors.

Yet another important object of this invention is to provide a new andimproved microwave reflector which can be economically shipped,installed, and maintained as compared to prior types of reflectors.

Another object of this invention is to provide a new and improved methodfor installing a microwave reiiector.

According to other features of this invention, the microwave retlectoris comprised of a series of extruded channel-shapedl panels ofessentially identical cross-sectional configuration which panels havemeans disposed adjacent from faces in a common plane. These panels alsohave means at outer ends of panel legs permitting the panels to besnapped into assembly in side-by-side relation. The panels are yfurtherprovided with means for securing them Patented Apr. 19, 1966 to preventlongitudinal movement of the panels relative to one another.

G ther objectsand -features of this invention will more lfully becomeapparent in view of the following detailed description taken inconjunction with the accompanying drawings illustrating therein severalembodiments and in which: v

FIGURE l is a fragmentary perspective view of a tower having our newmicrowave reliector thereon;

FIGURE 2 is a detailed perspective view of a Vernier adjustmentmechanism;

FIGURE 3 is an enlarged rear View of the microwave reflector;

FIGURE 4 is a fragmentary cross-sectional View taken substantially onthe line IV-IV looking in the direction indicated by the arrows as seenin FIGURE 3;

FIGURES is an enlarged fragmentary view similar to FIGURE 4 onlyillustrating a modified type of reflector;

FIGURES 6, 7, and 8 are enlarged end views of a pair of reliector panelsillustrating the manner of assembly;

FIGURE 9 is an enlarged side view of the reflector;

FIGURE l0 is an enlarged detailed View of a portion of the structure ofFIGURE 9; and

FIGURE 1l is an enlarged cross-sectional view taken substantially on theline XI-XI looking the direction indicated by the arrows as seen inFIGURE 10.

As shown on the drawings:

The reference numeral 7 indicates a verticahtype tower having a seriesof vertical tower legs 8 which may be braced in any suitable manner bybrace straps 9. According to this invention, we have provided a new typeof microwave reector 10 that is adapted to be mounted on the tower 7 orany suitable supporting structure. The reflector is comprised of aseries of strip type intermediate panels 11 and end panels 11 and 11"(FIGURE 4). These panels are preferably formed as extrusions from alight weight metal such as aluminum and are each of a channel-shapedconfiguration. Excellent results may be obtained by forming each of thepanels so as to have a width no longer than 6 inches and a length of 8or l12 or l5 feet, depending upon the required size of the reliector.

The panels 11, 11', and 11 are formed with means permitting the panelsto be snapped into vassembly together in side-by-side relation asindicated at 12 in FIG- URES 6-8. To this end, the channels each includea face or face portion 13 having shorter .and longer end channel legs 14and 15 at opposite ends of the face portion 13. These legs extendrearwardly generally at right angular relation with respect to the faceportion 13. At the inner ends of the legs 14 and 15', the legs areprovided :with shorter Iand longer detlectable `terminal snaplock legs16 and 17. The legs 16 and 17 are disposed in right angular relationwith respect to the legs 14 and 15 and in generally parallel relationwith respect to the face portion 13. The shorter deectable leg 16 isformed on the inner end of the shorter end channel leg 14 while thelonger dellectable leg 17 is formed on the longer end channel leg 15.The legs 16 and 17 extend away from the channel legs 14 and 15 in thesame general direction so thatwhen the panels 11 are joined together,the channel legs 14 and 15 are disposed in side-by-side relation whilethe terminal legs 16 and 17 are also disposed in side-by-side relationwith the shorter leg 16 underlying the longer leg 17.

The means 12 includes a retaining or locking shoulder 18 on the longerleg 17 and a retaining or locking shoulder 19 on the shorter leg 15.When the channels are engaged in assembly together, the shoulders 18 and19 are engaged in confronting relation. In order to maintain theshoulders 18 and 19 in locked engagement for locking the panels 11together, each panel has a hook or hook-shaped pivot leg 20. The pivotleg 20 is disposed generally in the plane of the front face 13 and ingenerally parallel relation with respect to the longer deflectableterminal leg 17. The pivot leg extends away from the longer channel leg15 in the same direction as the terminal leg `17 and is also disposed ingenerally right angular relation with respect to the channel leg 15. Theopposite end of the panel 11 is formed with a thickened metal mass 21 atthe juncture between the face portion 13 and the shorter channel leg 14.A pivot groove 22 is provided in the thickened metal mass 21 which ispreferably of a configuration corresponding to the shape of the portionof the pivot leg to be nestingly engaged in the pivot groove. Asillustrated, the pivot groove 22 is of a hook-shaped configuration.After the panels 11 have been formed to shape, they may be joinedtogether by engaging the hook-shaped pivot leg 2t) in the pivot groove22 as shown in FIGURE 6. The end channel legs 14 and 15 are then pushedtogether until the shorter end channel legs 14 and 16 are brought intoengagement with the longer channel legs 15 and 17 whereupon the lockingshoulder 19 is caused to be snapped over and behind the retaining orlocking shoulder 1S on the longer leg 17. As the legs 14 and 15 arebrought together, the panels being joined are pivoted at the area of thehook-shaped leg and the groove 22.

The locking shoulders 1S and 19 may be brought into engagement by theapplication of manual force to the opposite ends of the panels 11 beingjoined. With some types of panels 11, such as where the panels have arelatively long length, channel-lock pliers (not shown) or any othersuitable tool may be employed for pressing the legs 14 and 15 intoengagement together. Where pliers are used, wood blocks are preferablydisposed on opposite sides of the legs 14 and 15 so that the legs 14 and15 may be pressed together Without damaging the panels. After theshoulders 18 and 19 have been engaged in locked relation, it Will beappreciated that the hook-shaped leg and the groove 22 cooperate withthe iaterengaged shoulders 1S and 19 in securing the adjacent contiguouspanels together. The panels may be disengaged from one another bysliding them lengthwise in opposite directions with respect to oneanother until the hook-shaped leg 20 is disengaged from t-he groove 22and the shoulder 19 is disengaged from the shoulder 13. In order toreinforce the panels `11 and to insure that the panels will afford aflat reflective face when assembled, the underside of the face portion13 is provided with reinforcing ribs 23 which extend the length of thepanels 11.

The end panels 11 and 11" differ from the intermediate panels 11 so thatportions of `the channel legs and terminal legs are omitted. Withrespect to the end panel 11', the panel onlyhas a relatively shortchannel leg 14 and is not provided with any terminal leg. This panel 11'is otherwise the same as the panel 11. The other end panel 11 has ashortened channel leg 15" and the terminal leg is entirely omitted.Means is provided for securing the panels 11, 11 and 11" against endwiselongitudinal movement with respect to one another. This means includes apair of end frame members or channels 24, 24 and a pair of side framemembers or channels 25, 2S as shown in FIGURES 3 and 4. The framemembers or channels 24 and 25 are disposed in engagement about the foursides of the interengaged panels 11, 11 and 11 and mitered corner joints26 are disposed at the juncture of the frame members. Corner plates 27are mounted on opposite sides of the reector 10 over the corner joints26 and connecting fasteners or bolts and nuts are provided to attach thepanels 11, 11' and 11 with the associated frame members 24 and 25 andwith the associated corner plates 27. The panels 11, 11 and 11" mayextend transversely or longitudinally of the reliector 10, as desired.In order to further reinforce the reflector 1t), an intermediate angularframe brace 29 is mounted at the rear side of the reflector 10 andsecured by fasteners 30, which may comprise bolts and nuts, to therespective panels. The fasteners may be engaged with the terminal legs16 and 17.

A series of fasteners 30 which may comprise nuts and bolts is providedfor securing the end channels 24, 24 with legs 14 and 15" of the endpanels 11 and 11". Either of the fasteners 30 are provided to secure theside channels 25, 25 with opposite ends of the panels 11.

Mounted at the rear side of the reflector 10 is a coneshaped reinforcingstructure 35. This reinforcing structure not only serves to brace thepanels 11, 11 and 11", but also is adapted to coact with the tower inthe suspension of the reflector fromthe tower as will be described infurther detail hereafter'. The structure 35 includes four reinforcingIangular braces S16-39, inclusive. These braces extend from the fourcorners of the reilector 16 and are secured with the four corners of thereflector 10 by means of attachment straps 40. The opposite ends of thebraces 36-39 are joined at the apex of the cone-shaped reinforcingstructure with plates 41 and 42 which comprise a one piece T-shapedstructure. The braces may be bolted or otherwise suitably secured withthe planes 41 and 42. In order to reinforce the braces 36-39, sets oftubular truss straps 43, 44 and 45 are provided on opposite sides of thestructure with one set of straps reinforcing the braces 37 and 39 andthe other set of straps reinforcing the other set of braces 36 and 38.Each set of straps is joined with the reflector 10 and with associatedbraces by means of truss strap brackets 45, 47 and 43 and by means offasteners 49 such as bolts and nuts. The straps have flat ends,according to other features of this invention, which are hereafterdescribed in further detail.

In order to further reinforce the reector 10, a pair of adjustmenttubular arm assemblies 50 and 51 are joined with attachment plates 52and 53 on the intermediate frame brace 29 by suitable fasteners 5G and51' as are i1- lustrated in FIGURE 9. Opposite ends of the adjusment armassemblies 50 and 51 are suitably attached with the plate 41 at the apexof the cone-shaped reinforcing structure 35 (FIGURE l), by the nuts andbolts 5d and 51' according to other features of this invention, tubulararms 50 and 51 have fiat tubular ends 50a and 51a at opposite ends as dothe straps 43, 4d and 45 to facilitate attachment and to permit properdrainage of the tubes. The flat end detail for the arm 51 is shown inFIGURES 10 and 11 and it will be appreciated the flat ends on the otherarms and straps are the same. The laminated flat tube end 51a hastubular portions 51.5, 51b at opposite sides to permit water drainage asshown in FIGURE 11. Adjustrnent nuts 50a and 51a are provided to securethe adjustable arm assemblies in adjusted position to firmly connect thecentral area of the reflector 19 with the apex of the cone-shapedreinforcing structure.

A pair of angular reflector mounting brackets 54 and 55 are mounted onthe tower 7 by means of C-clamp fasteners 56. The cone-shapedreinforcing structure 35 has a pivot pin 57 that extends through theplate 42 generally at the cone apex and through the upper reflectormounting bracket 54 for suspending the reector from this bracket. A nut5S is mounted on the pivot pin 57 to {irmly attach the pivot to themounting bracket 54 after the reflector 16 has been moved into itsdesired adjusted position.

At an underside of the reector 10 and more particuing angles 59 and 60is mounted. A Vernier adjustment mechanism 61 is pivotally mounted andsecured at one end by means of a bolt and nut fastener 62 .to the lowerreector mounting bracket 55. A slidable carriage 63 is mounted on theVernier adjustment mechanism 61 which has a pair of angular plates 64and 65 that are joined with the mounting angles. A lower end of thereflector is adapted to be moved on the carriage 63 back and forth alongthe Vernier adjustment mechanism in order to vary the ground angle ofthe reflector face. The face may be adjusted from 35 to 51 degrees andis commonly disposed in a 45 position. The carriage 63 is attached to athreaded steel rod 66 which is supported at opposite ends on arectangular Vernier frame 67. Bolts 68 and 69 are provided for securingthe rod 66 with the frame 67. The carriage 63 may be movedlongitudinally of the bolt 67 by adjustment of the fasteners 70 and 71.A carriage plate 72 is mounted on the underside of the carriage 63 andis engaged against an underside of frame flanges 73 and 74. When thefasteners 70 and 71 are loose, the carriage 63 and the carriage plate 72may be moved longitudinally along the length of the rod. After thecarriage 63 has been moved into its desired position, the fasteners 70and 71 can be drawn .tight to secure the carriage 63 and the carriageplate 72 into tight engagement with opposite sides of the frame flanges73 and 74.

The method features of our invention have already been described for themost part in connection with the description of the reflector componentsand the manner in which such components are assembled. summarizingbriefly, the tubes 44, 45, 46, 50 and 51 are all formed from a metalmass and the ends of the tubes are then shaped to press intermediateportions of the tube ends flat forming the laminated flat portion 51awhile contemporaneously shaping or holding the shape of the sideportions of the tube ends so that the side portions will be tubular andin communication with the remainder of the tube to permit water drainagetherethrough. The tubular side portions are identified at 51b, 51b inFIGURE 1l. In connection with the method of forming the reflector 10,the panels 11 are individually formed preferably in an extrusion processwith the snap locking means 18 and 19 and the pivoting and locking means20 and 22 being formed during the extrusion process. The panels are thensnapped together and the side or panel margin reinforcing structurecomprising channels 24, 24 and 25, 25 is mounted at the margins of thepanels to resist longitudinal movement of the panels. The aforesaidchannels may be secured lby means of the fastener illustrated in FIGURE4 or by means of the fastener 30" as illustrated in PlG- URE 5. Thecone-shaped reinforcing structure 35 is then mounted at the rear side ofthe reflector. The structure is provided with a pivot 57 at its upperend and an adjustment mechanism 61 is mounted at a bottom end of thepanels 11 whereby the reflector can be pivotally mounted on a tower andthe adjustment mechanism 61 can be em` ployed to vary the angle of thefront reflective face of the reflector 10.

The reflector disclosed herein has a number of advantages over priortypes of reflectors among which are: (l) greater face fiatness, (2) morerigid construction which insures longer life and decreases maintenancecost, (3) freight costs are substantially reduced and (4) the reflectiveface is free of rivet and bolt heads except at the margins thereof.

Although minor modifications might be suggested by those versed in theart, it should be understood that we wish to embody within the scope ofthe patent warranted hereon, all such modifications as reasonably andproperly come within the scope of our contribution to the ar-t.

We claim as our invention:

1. A microwave reflector including a reflective face that is of aknockdown construction and that is uniformly flat and free of welds andbolt heads and is comprised of a series of reflector channels havingchannel legs which are snappedvtogether in side-by-side relation, agenerally coneshaped reinforcing :structure projecting from a rear sideof the reflector, and means for attaching the cone-shaped structure` toa supporting structure such as a tower.

2. A microwave reflector including a reflective .face that i-s of aknockdown construction and that is uniformly flat and free of welds andbolt heads and is comprised of a series of reflector channels havingchannel legs which are snapped together in side-by-side relation, agenerally cone-shaped reinforcing structure projecting from a rear sideof the reflector, and means for attaching the generally cone shapedstructure to a supporting structure such as a tower, the reflectorchannels each having a length several times greater than its width andbeing of generally uniform size.

3. A microwave reflector including a reflective face that is `of aknockdown construction and that is uniformly flat and free of welds andbolt heads and is comprised of a series of reflector channels havingchannel legs which are snapped together in side-by-side relation, agenerally cone-shaped reinforcing structure projecting from a rear sideof the reflector, means for attaching the generally cone-shapedstructure from its apex to a supporting structure such as a tower, and aVernier adjustment mechanism mounted on a supporting structure such as atower and supporting a lower end of the reflector enabling a lower endof the reflector to be moved relative to the apeX of the generallycone-shaped structure for adjusting the reflective face.

4. A microwave reflector including a reflective face that is of aknockdown construction and that is uniformly flat and free of welds andbolt heads and is comprised of a series of reflector channels havingchannel legs which are secured together in side-by-side relation, agenerally coneshaped reinforcing structure projecting from a rear sideof the reflector, and means for attaching the generally cone-shapedstructure to a supporting structure such as a tower.

5. A microwave reflector including a reflective face that is of aknockdown construction and that is uniformly flat and free of welds andbolt heads and is comprised of a series of reflector channels havingchannel legs which are secured together in side-by-side relation, agenerally cone-shaped reinforcing structure projecting from a rear sideof the reflector, means for attaching the generally cone-shapedstructure to a supporting structure such as a tower, framing meanscomprising marginal frame chan nels about the perimeter, and meansjoining said frame channels with the reflector channels.

6. A microwave reflector including a reflective face that is of aknockdown construction and that is uniformly flat and free of welds andbolt heads and is comprised of a series of reflector channels havingchannel legs which are secured together in side-by-side relation, agenerally cone-shaped reinforcing structure projecting from a rear side'of the reflector, and means for attaching the generatlly cone-shapedstructure to a supporting structure such as a tower, the reflectorchannel-s each having a length several times greater than its width andAbeing of generally uniform size.

7. A microwave reflector including a reflective face that is of aknockdown construction and that is uniformly flat and free of welds andbolt heads and is comprised of a series of reflector channels havingchannel legs which are secured together in side-by-side relation, agenerally cone-shaped reinforcing structure projecting from a rear sideof the reflector, means for attaching the generally cone-shapedstructure to a supporting structure such as a tower, and adjustablemeans connected between an apex of the cone-shaped reinforcing structureand a back side of said channels.

8. A microwave reflector including a reflective face that is of aknockdown construction and that is uniformly flat and free of welds andbolt heads and is comprised of a series lof reflector channels havingchannel legs 2,968,033 1/ 1961 Kreitzberg 343-916 X which are shapedtogether in side-by-side relation, a gen- 2,976,888 3/ 1961 Merriman285-137 erally cone-shaped reinforcing structure projecting from3,085,367 4/1963 De Ridder et al 189-34 X a rear side of the reector,means for attaching the gen- 3,100,556 8/ 1963 De Ridder 189-34 erallycone-shaped structure to a supporting structure such 5 3,111,203 11/1963 De Ridder 189-34 as a tower, framing means comprising marginalframe 3,111,205 11/ 1963 Gresham 189-34 channels about a perimeter ofthe reflector, corner brackets FOREIGN PATENTS at corners of thereflector, and knockdown means joining the brackets with the framechannels and the reflector 2161556 12/1941 swltzerlandchannels inunitary assembly. 10 OTHER REFERENCES Tower Construction Co., catalog,Oct. 1, 1957, pages References Cited by the Examiner 3, 4, 5, 6 and 121n Microwave Reectors Section.

UNITED STATES PATENTS 2,189,201 2/1940 Flader 287-54 HERMAN KARLSAALBACH, Primary Examiner.

1. A MICROWAVE REFLECTOR INCLUDING A REFLECTIVE FACE THAT IS OF A KNOCKDOWN CONSTRUCTION AND THAT IS UNIFORMLY FLAT AND FREE OF WELDS AND BOLT HEADS AND IS COMPRISED OF A SERIES OF REFLECTOR CHANNELS HAVING CHANNEL LEGS WHICH ARE SNAPPED TOGETHER IN SIDE-BY-SIDE RELATION, A GENERALLY CONESHAPED REINFORCING STRUCTURE PROJECTING FROM A REAR SIDE OF THE REFLECTOR, AND MEANS FOR ATTACHING THE CONE-SHAPED STRUCTURE TO A SUPPORTING STRUCTURE SUCH AS A TOWER. 